48DJ,DK,NP034-074
48FJ,FK,FP,JJ,JK,JP034-074
Accessory LP (Liquid Propane) Gas Conversion Kit
Installation and Start-Up Instructions
Part No. 50DJ902---571, 50DJ902---581, and 50DJ902---591
CONTENTS
GENERAL
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Installing Mechanical Components . . . . . . . . . . . 2
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Adjusting Gas Input . . . . . . . . . . . . . . . . . . . . . . . . 11
Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . 11
CONVERSION FROM LP GAS
TO NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . 13,14
These instructions cover the installation and start-up of a
propane conversion kit on 48DJ,DK,FJ,FK,FP,JJ,JK,JP,NP034074 gas heating/electric cooling units. Refer to Table 1 for
kit numbers and contents.
NOTE: Save all original natural gas parts in case conversion
back to natural gas should become necessary.
Table 1 — Propane Conversion Kit Contents and Part Numbers
UNIT
PART NO.
CONTENTS
Burner Orifices (No. 48 Spuds)
Crossover Tube with Orifices
Gas Pressure Switch
Nipple (1⁄8 in. x 11⁄2 in.)
Wiring Labels
Pilot Tube Label
Propane Conversion Label
Conversion Responsibility Label
Wires
Blue (6 in.)
Red (84 in.)
Connector
Spacer/Washer
Pop Rivets
Stainless Steel
Aluminum
Pilot Tube with Nut
Pilot Tube
Tee (Compression)
Elbow
Shield
Flue Restriction
Blockoff
Air Baffle
Screws
Ferrule
50DJ902---571
48DJE,FJE,FKE,FPE,JJE,
JKE,JPE,NPE034-048
HIGH HEAT AND
48DJD,DKD,FJD,FKD,FPD,
JJD,JKD,JPD,NPD054-074
LOW HEAT
50DJ902---581
LH32RF076 (6)
50DW504152 (1)
HK02LB016 (1)
CA01CA020 (1)
50DW504161 (2)
50DW504162 (2)
—
50DW504158 (1)
50DW504160 (1)
50DW504159 (1)
LH32RF076 (12)
50DW504152 (2)
HK02LB016 (1)
CA01CA020 (1)
50DW504162 (2)
50DW504163 (2)
50DW504164 (2)
50DW504158 (2)
50DW504160 (1)
50DW504166 (1)
LH32RF076 (18)
50DW504152 (3)
HK02LB016 (1)
CA01CA020 (1)
50DW504164 (2)
—
—
50DW504158 (3)
50DW504160 (1)
50DW504167 (1)
* (1)
* (2)
HY89SB020 (6)
* (10)
—
* (2)
HY89SB020 (4)
* (20)
—
* (2)
HY89SB020 (4)
* (30)
AV83JA180 (4)
AV83VA165 (4)
50DW404170 (2)
50DW504174 (1)
DC18CA051 (1)
DD10CA053 (1)
50DW504172 (1)
50DW502684 (1)
—
—
—
DC20CA051 (1)
AV83JA180 (8)
AV83VA165 (8)
50DW404170 (4)
50DW504174 (2)
DC18CA051 (2)
DD10CA053 (2)
50DW504172 (2)
50DW502684 (2)
50DW504208 (1)
50DW504209 (1)
AL79AV166 (4)
DC20CA051 (2)
AV83JA180 (12)
AV83VA165 (12)
50DW404170 (6)
50DW504174 (3)
DC18CA051 (3)
DD10CA053 (3)
50DW504172 (3)
50DW502684 (3)
50DW504208 (2)
50DW504209 (1)
AL79AV166 (6)
DC20CA051 (3)
48DJD,DKD,FJD,
FKD,FPD,JJD,JKD,
JPD,NPD034-048
LOW HEAT
48DJE,FJE,FKE,FPE,
JJE,JKE,JPE,NPE054-074
HIGH HEAT
50DJ902---591
*Indicates no part number for this item.
NOTE: Number in ( ) represent the quantity of each item included in the kit.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1
PC 111
Catalog No. 564-901
Printed in U.S.A.
Form 48-8SI
Pg 1
10-98
Replaces: 48D,N-3SI
Tab 1a
This conversion kit is to be installed by qualified service personnel in accordance with these installation instructions and all codes and requirements of the authority having jurisdiction, and in Canada, in accordance with
the requirements of the CAN/CGA (Canadian Gas Association) B149.1 and B149.2 Installation Code. Failure to follow these instructions could result in serious
injury or property damage. The qualified agency performing this work assumes responsibility for this conversion.
INSTALLATION
Turn off the gas supply, then the electrical power to the
unit before starting the installation. Tag the disconnect
switch with a suitable warning label. Electrical shock
can cause personal injury or death.
Installing Mechanical Components — Proceed
as follows to install the mechanical components contained
in the kit:
1. Open and remove gas section door.
NOTE: Perform Steps 2 through 22 for each burner section. There is 1 section on low heat 034-048 units, 2
sections on high heat 034-048 units and low heat 054074 units, and 3 sections on high heat 054-074 units.
2. Disconnect the gas line at the first union of the assembly. See Fig. 1 and 2.
3. Disconnect the plug in the wiring harness going to the
gas valve and rollout switch.
4. Disconnect the ignitor and sensor wires at the sparker
module (ICP). Label the wires prior to removing to ensure they will be reconnected properly.
NOTE: High heat consists of Sections 1-3. Low heat consists of Sections 1 and 2 only.
Fig. 2 — Gas Section Detail, Sizes 054-074
5. Remove the 2 screws which fasten the top of the burner
assembly to the flue box, and carefully remove the burner
assembly from the unit. See Fig. 3.
6. Disconnect the pilot tube from the gas valve. See
Fig. 4.
7. Disconnect the manifold (with the spuds attached) from
the burner assembly and remove the manifold assembly
with the gas valve attached. Remove the burners. See
Fig. 4.
8. Disconnect the burner bracket from the burner assembly and remove the burner bracket with the crossover
tube attached. See Fig. 4.
9. Remove the crossover tube from the burner bracket. Be
careful not to distort or damage the ignitor or sensor.
See Fig. 4 and 5.
10. Drill out the pop rivets holding the ignitor and sensor to
the burner bracket using a 1⁄8-in. diameter drill bit.
NOTE: High heat consists of Sections 1 and 2. Low heat consists of
Section 1 only.
Fig. 1 — Gas Section Details, Sizes 034-048
Fig. 3 — Flue Box Assembly
(Shown with Burner Assembly)
2
11. Remove screws holding ignitor shield to the burner bracket.
Install new shorter ignitor shield from kit. See Fig. 6.
12. Install new, dual-orifice crossover tube from accessory
kit onto the burner bracket. Be sure to install crossover
tube with spacers provided to space tube away from the
burner bracket as shown in Fig. 5.
13. Reinstall ignitor and sensor onto opposite side of burner
bracket. Be sure to install ignitor and sensor as shown
in Fig. 5 using spacers and pop rivet provided so that
gap is as shown.
14. Reattach the burner bracket to the burner assembly.
15. Remove the spuds from the manifold assembly and install the new no. 48 spuds from the accessory kit. Make
sure that the spuds are not cross threaded.
16. Adjust the primary air opening on all of the burners to
1⁄2 inch. See Fig. 7.
17. Reattach the manifold assembly to the burner assembly
with the burners in place. Be sure that the spring washers are in place between the burners and the spuds and
that the burners are aligned properly. Also check that
the rollout switch capillary is located properly. See
Fig. 4.
Fig. 5 — Burner Bracket Spacing
Fig. 4 — Burner Section Detail
Fig. 6 — Typical Burner Assembly Details
3
18. On 054-074 units only (Skip to Step 19 for 034-048
units):
a. Attach air baffle to the right side of the burner assembly FOR SECTION NUMBER ONE ONLY using screws provided. See Fig. 8 and 9.
b. Attach the block-off plate to the left side of the burner
assembly FOR SECTION NUMBER TWO (low heat
units) or SECTION NUMBERS TWO AND THREE
(high heat units) ONLY using screws provided. See
Fig. 6 and 10.
19. All units: Cut the old pilot tube and remove the threaded
compression fitting which connects to gas valve. Put the
compression fitting on the new pilot tube and slide on
the ferrule supplied with the kit. Connect the pilot tube
to the gas valve. Put the elbow removed from old crossover tube on one end of the new crossover. Put elbow
from kit on the other end of the new crossover tube. Connect new pilot tube and new compression tee as shown
in Fig. 6.
20. Apply pilot tube label from kit over the existing label
on the side of the burner assembly. See Fig. 11.
21. Reinstall burner assembly in unit. Reconnect plug and
sensor and ignitor wires.
22. Install 7⁄16-in. wide flue restriction on flue outlet using
pop rivets provided. On 034-048 units, remove larger
restriction plate and install new plate in the same place.
See Fig. 3 and 12.
23. Install low gas pressure switch from kit:
Remove tap plug from the inlet manifold. See Fig. 1
and 2.
24. Using joint compound, assemble switch and 11⁄2 in. long
nipple provided.
25. Install this assembly on the inlet manifold.
Fig. 7 — Primary Air Opening Adjustment
Fig. 8 — Air Baffle Location, Size 054-074 Units, Section 1 Only
4
NOTE: Dimension in [ ] are in inches.
Fig. 12 — Flue Restriction Plate
Wiring
48DJD,FJD,FPD,JJD,JPD,NPD034-048 UNITS (See Fig. 13)
1. Attach the two 84-in. long red wires supplied to the low
gas pressure switch (GPS).
2. Locate the red wire going from pressure switch (PS1) to
ICP1 terminal TH.
3. Remove the red wire from ICP1 terminal TH, and cut the
terminal off from the wire.
4. Connect stripped wire from the GPS to the red wire just
removed from ICP1 terminal TH using the connector provided. Connect the other red wire from the GPS to ICP1
terminal TH.
5. Remove the black (BLK) wire from gas valve terminal
W2, and insulate the terminal.
6. Install the 6-in. long blue jumper wire supplied between
terminal W1 and W2 on the gas valve.
48DKD,FKD,JKD034-048 UNITS (See Fig. 14)
1. Attach the two 84-in. long red wires supplied to the low
gas pressure switch (GPS).
2. Locate the red wire going from pressure switch (PS1) to
ICP1 terminal TH.
3. Remove the red wire from ICP1 terminal TH and cut the
terminal off from the wire.
4. Connect stripped wire from the GPS to the red wire just
removed from ICP1 terminal TH using the connector provided. Connect the other red wire from the GPS to ICP1
terminal TH.
48DJE,FJE,FPE,JJE,JPE,NPE034-048 UNITS (See Fig. 13)
1. Attach the two 84.-in. long red wires supplied to the low
gas pressure switch (GPS).
2. Remove the 2 orange (ORN) wires from limit switch relay (LSR) terminal 3. Connect the stripped wire from GPS
to the 2 ORN wires just removed using the connector
provided.
3. Connect the other red wire from the GPS to LSR terminal 3.
48DJD,DJE,FJD,FJE,FPD,FPE,JJD,JJE,JPD,JPE,NPD,
NPE054-074 UNITS (See Fig. 15)
1. Attach the two 84-in. long red wires supplied to the low
gas pressure switch (GPS).
2. Remove the orange (ORN) wires from limit switch relay
(LSR) terminal 3. Connect the stripped wire from GPS to
the ORN wire just removed using the connector
provided.
3. Connect the other red wire from the GPS to LSR terminal 3.
NOTE: All dimensions are in millimeters.
Fig. 9 — Air Baffle
NOTE: All dimensions are in millimeters.
Fig. 10 — Block-Off Plate
Note: Dimensions in [ ] are in inches.
Fig. 11 — Pilot Tube Label
5
LEGEND
CB
CR
CV
GPS
GR
HR
ICP
IDC
—
—
—
—
—
—
—
—
Circuit Breaker
Control Relay
Constant Volume
Gas Pressrue Switch
Gas Relay
Heater Relay
Ignitor Control Pack
Induced Draft Contactor
LS
LSR
MG
MGV
PIC
PL
PS
SEN
—
—
—
—
—
—
—
—
Limit Switch
Limit Switch Relay
Main Gas
Main Gas Valve
Product Integrated Controls
Plug Assembly
Pressure Switch
Sensor
Fig. 13 — Wiring Diagram, 48DJ,FJ,FP,JJ,JP,NP034-048 Units
6
CB
GPS
GR
HIR
ICP
IDC
LS
MG
—
—
—
—
—
—
—
—
Circuit Breaker
Gas Pressrue Switch
Gas Relay
Heater Interlock Relay
Ignitor Control Pack
Induced Draft Contactor
Limit Switch
Main Gas
LEGEND
MGV
PG
PGV
PL
PS
RS
SN
TB
—
—
—
—
—
—
—
—
Main Gas Valve
Pilot Gas
Pilot Gas Valve
Plug Assembly
Pressure Switch
Rollout Switch
Sensor
Terminal Block
Fig. 14 — Wiring Diagram, 48DK,FK,JK034-048 Units
7
CB
COM
CR
CV
GND
GPS
GR
HR
—
—
—
—
—
—
—
—
Circuit Breaker
Common
Control Relay
Constant Volume
Ground
Gas Pressure Switch
Gas Relay
Heater Relay
I
ICP
IDC
LS
LSR
MGV
NO
P
—
—
—
—
—
—
—
—
LEGEND
Ignitor
Ignitor Control Pack
Induced Draft Contactor
Limit Switch
Limit Switch Relay
Main Gas Valve
Normally Open
Plug
PGV
PIC
PL
PS
RS
SN
TB
TH
—
—
—
—
—
—
—
—
Pilot Gas Valve
Product Integrated Controls
Plug Assembly
Pressure Switch
Rollout Switch
Sensor
Terminal Block
Thermostat
Fig. 15 — Wiring Diagram, 48DJ,FJ,FP,JJ,JP,NP054-074 Units
8
48DKD,DKE,FKD,FKE,JKD,JKE,NKD054-074 UNITS (See
Fig. 16) AND 48FKE,JKE034-048 UNITS (See Fig. 14)
1. Attach the two 84-in. long red wires supplied to the low
gas pressure switch (GPS).
2. Remove the 2 orange wires from limit switch 2 (LS2)
terminal 3. Connect the stripped wire from GPS to the
orange wires just removed using the connector provided.
3. Connect the other red wire from the GPS to LS2 terminal 3.
2. Attach the propane conversion label from kit above the
unit rating plate on each corner post. See Fig. 17.
3. Attach the completed conversion responsibility label from
kit above the unit rating plate on the unit corner post. See
Fig. 18.
Table 2 — Wiring Label Diagram Usage
UNIT
48DK,FK,JK034-048
48DJ,FJ,FP,JJ,JP,
NP034-048
48DK,FK,JK054-074
48DJ,FJ,FP,JJ,JP
NP054-074
Labels — Attach the label diagrams included in the kit
as follows:
1. Attach wiring diagrams from kit over existing diagram
on the inside of the gas section access door and over the
existing diagram on the inside of the control box access
door. See Fig. 13-16 and Table 2 for the proper label diagrams for each unit.
CB
GND
GPS
HIR
I
—
—
—
—
—
Circuit Breaker
Ground
Gas Pressure Switch
Heat Interlock Relay
Ignitor
ICP
IDC
LS
MGV
PL
—
—
—
—
—
LEGEND
Ignitor Control Pack
Induced Draft Contactor
Limit Switch
Main Gas Valve
Plug Assembly
PS
RS
SN
TB
LABEL
DIAGRAM PROVIDED
50DW504161
QUANTITY
50DW504162
2
50DW504163
2
50DW504164
2
—
—
—
—
Fig. 16 — Wiring Diagram, 48DK,FK,JK054-074 Units
9
Pressure Switch
Rollout Switch
Sensor
Terminal Block
2
NOTE: Dimensions in [
] are in inches.
Fig. 17 — Propane Conversion Label
NOTE: Dimensions in [
] are in inches.
Fig. 18 — Conversion Responsiblity Label
10
4. Set unit control to call for heat.
5. Using pilot adjustment screw, adjust pilot until it is a soft
blue flame fully engulfing the sensor.
6. With unit operating and all burners fired, adjust manifold
adjustment screw on gas valve (See Fig. 19 and 20) for
10.5 in. wg. Turn screw clockwise to increase pressure,
or counterclockwise to decrease pressure.
7. Turn off gas and then electrical power to unit.
8. Remove manometer and replace plug in pressure tap.
9. Install cover screw on gas valve.
START-UP
Do not purge gas supply into the combustion chamber.
Do not use a match or other open flame to check for gas
leaks. Use a soap-and-water solution and check all gas
piping for leaks. Failure to observe these warnings could
result in an explosion causing personal injury or death.
Make certain that the gas supply pipe has been purged
and all gas piping has been checked for leaks before starting
the unit.
Checkout Procedure — Proceed as follows to test
the newly installed propane gas system operation:
1. Turn on gas to the unit.
2. Check for normal operation of the ignition system, including pilot operation. Adjust pilot pressure if required.
See Fig. 19 and 20.
3. Observe that the flames on each burner are light blue and
‘‘soft’’ in appearance, and that the flames are approximately the same for each burner.
If the gas supply pressure falls below the set point of the
pressure switch (approximately 5.5 in. wg), the gas valve
will close and shut off gas supply to the unit. Determine the
cause of low gas supply pressure and correct the condition.
Before leaving the installation, a complete operating cycle
should be observed to ensure all components are functioning properly.
Adjusting Gas Input — The original gas valve is qualified to operate on propane gas, but the regulator must be
adjusted for proper unit operation. See Table 3 for proper
gas pressures and inputs.
The burner orifices from the kit are sized for the correct
gas input when the heating value of the propane gas is
2500 Btu/cu ft with a specific gravity of 1.5 in. wg at a
manifold pressure of 10.5 in. wg. (The propane gas supply
pressure minimum is 11.0 in. wg, and the maximum is
13.6 in. wg.) Use a water manometer to measure the manifold pressure. If a spring manometer is used, make sure the
manometer is calibrated.
Proceed as follows to measure and set the manifold
pressure:
1. Turn off gas supply and then electrical power to the unit.
2. Remove pressure tap plug on burner manifold and connect manometer to unit. See Fig. 1 and 2.
3. Turn on electric power and gas to unit.
C
MGV
PGV
QC
THD
LEGEND
— Contactor
— Main Gas Valve
— Pilot Gas Valve
— Quick Connect
— Thread
NOTE: All dimensions are in inches.
Fig. 19 — 48DJD,DKD,FJD,FKD,FPD,JJD,JKD,JPD,NPD034-048 Low Heat (2-Stage) Valve
11
LEGEND
THD — Thread
NOTE: Dimensions in ( ) are in millimeters.
Fig. 20 — 48DJE,FJE,FPE,JJE,JPE,NPE034-048 and 48DJ,DK,FJ,FK,FP,JJ,JK,JP,NP054-074 (One-Stage) Valve
12
Table 3 — Gas Section Physical Data
UNIT
NO. OF ORIFICES
GAS SUPPLY PRESSURE (in. wg)
Natural Minimum
Maximum
Propane Minimum
Maximum
MANIFOLD PRESSURE (in. wg)
Natural
Propane
NATURAL GAS
Burner Orifice Part No.
Size (in.)
Pilot Orifice Size
Heating Input (Btuh)
PROPANE GAS
Burner Orifice Part No.
Size (in.)
Pilot Orifice Size
Upper
Lower
Heating Input (Btuh)
48DJD,DKD,FJD,
FKD,FPD,JJD,
JKD,JPD,NPD034-048
6
48DJE,FJE,FKE,
FPE,JJE,JKE,
JPE,NPE034-048
12
48DJD,DKD,FJD,
FKD,FPD,JJD,
JKD,JPD,NPD054-074
12
48DJE,FJE,FKE,
FPE,JJE,JKE,
JPE,NPE054-074
18
5.0
13.0
5.0
13.0
5.0
13.0
5.0
13.0
11.0
13.6
11.0
13.6
11.0
13.6
11.0
13.6
2.9
10.5
3.0
10.5
3.0
10.5
3.0
10.5
LH32RF125
1⁄8
48
264,000
LH32RF125
1⁄8
48
529,000
LH32RF125
1⁄8
48
540,000
LH32RF125
1⁄8
48
810,000
LH32RF076
48
LH32RF076
48
LH32RF076
48
LH32RF076
48
79
61
264,000
79
61
529,000
79
61
540,000
79
61
810,000
8. Using pilot tube and elbow, connect crossover tube to
gas valve pilot connection.
9. Reassemble burner assembly and install in unit.
10. Remove all LP labels from unit.
11. a. On 48DJD,FJD,FPD,JJD,JPD,NPD034-048 units, remove blue jumper wire from between terminals W1
and W2 on the gas valve. Reattach black wire to terminal W2.
b. On all 054-074 units, remove flue restriction on flue
outlet.
12. Jumper low gas pressure switch.
13. Sizes 034-048 only: Fabricate and install flue restrictor(s) in place of restriction(s) already in place. See
Fig. 21 and 22.
14. Turn on main gas supply.
15. Adjust pilot flame and adjust gas input rate according to
Table 3.
16. Check for normal operation of the ignition system. Several complete operating cycles should be observed before leaving the installation to ensure all items are functioning properly.
CONVERSION FROM LP GAS TO
NATURAL GAS
If the original natural gas parts were not saved when
the unit was converted from natural gas to liquid propane
(LP) gas, refer to Table 4 for the necessary parts to order
from Carrier. Contact your local representative for more
information.
Refer to Installation section for detailed instructions on
how to accomplish the steps below.
1. Remove burner assemblies from unit.
2. Remove LP burner spuds and crossover tube.
3. Remove ignitor and sensor and reattach to opposite side
of burner bracket.
4. Install natural gas crossover tube. Do not use spacer washers used on LP crossover tube.
5. Install natural gas burner spuds.
6. Remove blockoff and air baffle from 054-074 unit burner
assemblies. See Fig. 6, 8, 9 and 10.
7. Adjust burner primary air opening to 5⁄8 inch. See
Fig. 7.
Table 4 — Part Numbers for Conversion from LP Gas to Natural Gas
UNIT
DESCRIPTION
Crossover Tube With Orifice
Burner Orifice (Spuds)
Pilot Tube (Valve to Crossover)
48DJD,DKD,FJD,
FKD,FPD,JJD,JKD,
JPD,NPD034-048
LOW HEAT
48DJE,FJE,FKE,FPE,
JJE,JKE,JPE,NPE034-048
HIGH HEAT AND
48DJD,DKD,FJD,FKD,FPD,
JJD,JKD,JPD,NPD054-074
LOW HEAT
48DJE,FJE,FKE,FPE,
JJE,JKE,JPE,NPE054-074
HIGH HEAT
50DW500277 (1)
LH32RF125 (6)
50DW400276 (1)
50DW500277 (2)
LH32RF125 (12)
50DW400276 (2)
50DW500277 (3)
LH32RF125 (18)
50DW400276 (3)
13
NOTE: Dimensions are in mm. Dimension in [ ] are in inches.
Fig. 21 — Flue Restrictor Plate, 48DJD,DKD,FJD,FKD,FPD,JJD,JKD,JPD,NPD034-048 (one required)
NOTE: Dimensions are in mm. Dimensions in [ ] are in inches.
Fig. 22 — Flue Restrictor Plate, 48DJE,FJE,FKE,FPE,JJE,JKE,JPE,NPE034-048 (2 required)
14
Copyright 1998 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1
PC 111
Catalog No. 564-901
Printed in U.S.A.
Form 48-8SI
Pg 16
10-98
Replaces: 48D,N-3SI
Tab 1a